ION EXCHANGE INDIA LTD

STANDARD SYSTEMS DIVISION

WELDING REPAIR & RUBBER RE-LINING PROCEDURE FOR

DEFECTIVE SAC VESSEL

DOC NO : IEI/JSW/SAC/RP-001
REV : 00
DATE : 28.04.2016

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 ION EXCHANGE INDIA LTD DOC NO : IEI/JSW/SAC/RP-001

WELDING REPAIR & RUBBER RE-LINING REV : 00

PROCEDURE FOR DEFECTIVE SAC VESSEL PAGE : 2 of 8

CONTENTS

1. SCOPE

2. PURPOSE

3. REFERENCES

4. ASSESSMENT OF DEFECTIVE VESSEL

5. REQUIREMENT OF TOOLS

6. PREMILIMINARY ACTIVITIES

7. EDGE PREPARATION

8. PREPARATION FOR WELDING

9. FIT UP INSPECTION

10. WELDING

11. POST WELDING INSPECTION

12. NDT

13. RUBBER LINING

14. PAINTING

15. HANDING OVER

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1. SCOPE

This procedure relates to the requirements of the Welding Repair & Re-Rubber Lining of
Defective SAC Vessel at M/s JSW Ltd, Bellary.

2. PURPOSE

This procedure provides for assessing the activities for Welding Repair & Re-Rubber Lining of
Defective SAC Vessel. This guidance is based on the requirements of the Quality Assurance
plan (QAP), Internal Test Procedures (ITP), and as per applicable codes and standards.

3. REFERENCES

ASME SEC VIII div.1, IS-2062 (2011), IEI Good Engineering Practice, IS-4682 (Part-1) and
other standards and specifications

4. ASSESSMENT OF DEFECTIVE VESSEL

1) Authorized Inspection Engineer shall assess the Vessel for the Root Cause for the
Crack occurred in the vessel to select the suitable methods of Repairing.

2) Inspection of physical appearance, straightness, flatness, rust, corrosion and other

deposits.

3) Inspection Engineer shall prepare a detailed report on the Root Cause and Remedy
and the same should be submitted to the Client for their review & acceptance.

5. REQUIREMENT OF TOOLS

Before starting the repair work it is advised to ensure the required machineries are in
place like welding machine, grinding machine, cutting torch, gas, welding electrodes,
PPE, Tools & Tackles, adequate power supply.

6. PREMILIMINARY ACTIVITIES

Engineer and his assigned contractor shall ensure the vessel is isolated from other units.
Required connections shall be dismantled from the vessel in order to free it from
external disturbances.
Resin and all internal attachments inside the vessel shall be removed and kept at the
recommended location for reuse.
Remove the rubber lining for 300mm on either side of weld joints by means of chipping
& grinding to avoid the fire and unwanted fumes during welding & grinding. Additional
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care to be taken during this process as there should not be any trace of rubber and
bonding agents (solution) on the internal surface of vessel.

Rest of the rubber lined portion near & under to the weld joint shall be covered with
high temperature, heat and flame resistant thermal insulating fibreglass cloth to have
better thermal insulation during cutting, welding and grinding. This will protect the
rubber lined areas from flames under the joint to be repaired.

Outside it is recommended to remove the painting for 200mm on either side of welding
by means of chipping & grinding to avoid burning of paints applied and to avoid
unwanted fumes.

If client feels the location is confined and the rework cannot be done at that particular
location then the vessel should be taken out to a required place for suitability.

By seeing the photographs the crack observed is only on the welded portion hence the
same plates in rolled condition can be used as such for repairing work. Edges that are
subsequently incorporated into a welded joint are to be inspected for any irregularities
which may interfere with the attainment of the requisite weld acceptance standards.
Such irregularities are to be rectified by grinding or other approved means.

All edges, which in the final structure have not been incorporated into a welded joint,
are to be inspected for irregularities and are to be dressed smooth by grinding.

After cutting, all slags, scales and other harmful matters shall be removed by grinding.
Defective cutting edges to be repaired by light welding and ground flush before
proceeding to next process.

7. EDGE PREPARATION

The size and type of all weld joints are to be in accordance with the approved drawings. The
requirements for each type of joint i.e. full penetration butt etc. will be found in the
relevant specification.

Edge preparations prepared and used in production shall comply to the following.

a. the design requirements

b. such edge preparations do not impair adherence to the full welding requirements.

c. weld soundness to the agreed acceptance standard is achieved;

d. they are shown on approved weld procedures

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8. PREPARATION FOR WELDING

1. Fit Up:

a. Prior to welding, fit the plates closely; and during welding, hold them firmly together.

b. Tack weld or clamp in place the edges of butt joints in proper alignment and hold
throughout the welding process. If the clamping is not sufficient use dogs, clips, lugs, or
equivalent devices welded to the steel plate for the purpose of forcing it into position.

c) Take particular care in aligning the edges to be joined so that complete penetration
and fusion at the bottom of the joint is accomplished. The offset in a butting edges shall
not exceed 1/16-inch at circumferential and spiral seams and shall not exceed 1/32-inch
at longitudinal seams.

2. Cleaning:

a. Prior to welding, clean the surfaces of plates to be welded to remove scale and rust
for a distance of not less than 1-inch and of all oil or grease for a distance of not less
than 3 inches from the welding edge and on both sides of the plates.

b. Remove grease or oil with lye or other solvent. Do not use kerosene or any heavier
petroleum solvent which are inflammable.

c. Grinding or Cleaning shall preferably be done prior to any tack welding of the plates.

d. When it is necessary to deposit metal over a previously welded surface, remove any
scale, slag, or welding flux thereon by a roughing tool, chisel, air chipping hammer, or
other means to prevent inclusion of impurities in the weld metal.

9. FIT UP INSPECTION

1) Bevelling test

Measure the bevel shape, dimensions, angles, etc., using the angle gauge,
thickness gauge, etc., according to the approved drawings. Unless the bevel
shape dimensions, etc., are indicated in the drawings.

2) Tack welding test

After aligning the shell, ensure whether its curvature is formed correctly.

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10. WELDING

Welding shall be carried out as per the approved WPS and Procedure. Extra care to be
taken to avoid any distortion during welding. It is recommended to carry out 10% DP
test for the back chipping to ensure the soundness of welding.

11. POST WELDING INSPECTION

Dimensional inspection shall be ensured post welding for further processings

- For the dimensional inspection, measure the major dimensions using instruments
such as tape measure, templates etc., according to the approved drawings to check
compliance with tolerances or relevant specifications indicated in the drawings.

- During the appearance and shape inspection, inspect the welds with the naked eye
and compare with the drawings according to the specifications.

- Check to ensure the final dimensions meet the Drawing requirement.

12. NDT

Post dimensional Inspection activities involving NDT shall be carried out as per
procedures. It is recommended to go for 100% DP test on the outside welded surface to
ensure the welding integrity as there is no chance of conducting Hydro Test since the
rubber lining does exist.

Once the DP test is passed the requirement and the solvents are removed from the
weld portions, the vessel can be taken for Rubber Lining Process.

13. RUBBER LINING

13.1 Surface Finish Required

Weld surfaces shall be ground & smooth. All weld joints shall be free of
Undercuts, Cracks, Porosity, Surface cavities & Lack of fusion which all affects
the lining apparently.

The surfaces shall be free from any foreign matter such as weld flux, residue,
sliver, oil, grease, salt etc. prior to blast cleaning.

Sharp edges and welds shall be rounded or smoothened by grinding. Hard

surface layers (e.g. resulting from flame cutting) shall be removed by grinding
prior to lining.
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13.2 Surface Preparation

Firstly, the surface of the repaired area to be rubber-lined should be visually

inspected. This is to check for sharp edges, uneven weld-joints or any other
deformities, which could hamper the lining process.

Then those areas need to be cleaned by means of Emery Papers in order to

remove the existing lining, presence of bonding solutions etc if any.

The surface should be thoroughly cleaned with clean dry compressed air, or a
clean dry brush.

13.3 Selection of Rubber Sheet

Rubber sheet shall be pre-vulcanized. Thickness shall be as per the Drawing

requirement and it should not contain any damages and the compound shall
meet the requirement of IS-4682 (Part.1) Natural Rubber. Hardness of the
rubber sheet shall not exceed 60 Shore-A.

13.4 Lining Technique

Cut the Pre-vulcanized Rubber sheets to suit the repaired portion and make teh
edges to 30-45 angle taper.
Existing lining shall be cut to taper to 30-45 angle to match with the new rubber
sheet to have a better bonding and matching.

Apply the Cold Bonding Rubber Solution on the cleaned surface as well as teh
rubber sheet and leave it for minimum 4 hours for curing.

After applying the 1st coat, continue the 2nd coat as given above and join the
sheets on the metal surface where the repair was attended.

Apply the pressure on the surface of the rubber sheet to have uniform seating
and better bonding.

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13.5 Inspection & Testing

Check the lining and surface visually for any visual defects.

Conduct the Spark Testing as per the recommended practice. (i.e 5KV per mm of
Thickness) and ensure there is no spark leak during testing.

Keep the lining unused for minimum 24 hours for proper curing inside and the
same can be taken for service after completion of curing.

14. PAINTING

Outer surface of vessel where the repair work is done should be cleaned thoroughly by
means of Emery or Sandering wheel and Painting shall be applied as per the approved
Drawing/Spec requirement.

15. HANDING OVER

The vessel welding repair and re-lining shall be shown to the clients representative for
their acceptance. Handing over of the equipment shall commence based on their
acceptance and accordingly MOM shall be prepared for reference.

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